Wall structure



April 11, 1944. R. KALKUscH 2,346,170

WALL STRUCTURE Filed May 29, 1939 2 Sheets-Sheet l .-I F .1 o y@ #y I?n// Z1 ,29 I Wm" April 11, 1944.V

R. KALKUSCH WALL STRUCTURE Filed May 29, 1939 2 Sheets-Sheet 2 JgaPatented Apr. 11, 1944 UNITED' STATES PATENT oFFlcE WALL STRUCTURERudolph Kalkusch, Chicago, lll. Application May 29. 1939, Serial No.276,360

4 Claims.

The present invention relates to wall structures, and is particularlyconcerned with improved wall structures adapted to be used for glassbricks or blocks, as well as ordinary brick, compressed brick, orconcrete blocks. The glass bricks which are used for making decorativewall structures are particularly diil'icult to lay or install in asatisfactory and permanent manner because the glass is inherently of adiiferent character from ordinary bricks and concrete blocks.

The glass bricks or blocks are not particularly adapted to carry load,and they are not adapted to absorb moisture from the mortar or masticused for joints in the manner that is done by ordinary bricks. Suchglass blocks have been provided with roughened external surfaces adaptedto engage the mortar or mastic, but the methods of the prior art oflaying up such glass blocks are unsatisfactory, and even with the utmostskill it is diiiicult and practically impossible to secure uniformjoints between such glass blocks and to secure a satisfactory job.

'Ihe glass block wall parts of the prior art are particularly unstable,and may be demolished with the application of very little force, as thestructure does not have the strength which is necessary to sustain sucha wall.

One of the objects of the invention is the provision of an improved wallstructure particularly adapted for glass blocks, but equally adaptablefor other bricks or blocks, by means of which a high degree ofuniformity of location of the bricks or blocks and of the dimensions andcharacteristics of the joints is assured.

Another object of the invention is the provision of an'improved jointfor wall structures, including glass bricks, blocks, or other materials,by means of which the strength of the wall is greatly increased and theload may be taken off the individual blocks and sustained by a jointstructure that is peculiarly adapted to carry the load.

Another object of the invention is the provision of an improved methodof making wall structures by means of which more uniform and strongerjoints may be provided and the load of a glass brick wall may be takenby the joint structures.

Another object of the invention is the provision of an improved pre-cast'joint structure for walls laid up in courses, which may be reinforced,and which may tie the whole wall together, align the blocks or bricks,sustain the weight of the individual blocks or bricks. and assure theprovision sions and strength.

Another object of the invention is the provision of an improved wallstructure and pre-cast joint structure, by means of which waste'of maofjoints of uniform dimenl vision of improved aligning and spacing devicesof which the spacing of the joints is automatically predetermined anduniform joints are assured.

Another object of the invention is the provision of an improved wallstructure including uniform pre-cast joints, by means of which theprevent the separation of the facing from the rest of the wall.

Another object of the invention is the provision reinforcing and brokenjoints between the pre-cast joints and the blocks or bricks of which thewall is composed.

Another object of the invention is the provision of an improved wallstructure, including pre-cast reinforced joint members in which thehorizontal joint members are adapted to act Yto tie the bricks or blocksof the wall together longitudinally of the wall, and the vertical jointmembers are adapted to act as load bearing struts for taking the loadolf the blocks, if blocks are employed which are not adapted to bear aheavy load,

Other objects and advantages of the invention following description andthe accompanying drawings, in which similar characters of referenceindicate similar parts throughout the several views.

Referring to the two sheets of drawings,

Fig. 1 is a fragmentary view in perspective of a glass block wallprovided with simple precast concrete joints constructed according tothe invention;

Fig. 2 is a full sized fragmentary elevational view of the intersectionof two joints as shown in Fig. 1;

walls are laid up according` member of the type of the outer surfaceFig. 3 is a sectional view, taken on the plane of the line 2-3 of Fig.2, looking in the direction of the arrows;

Fig. 4 is a view in perspective, partially broken away, to show thereinforcement of a horizontal pre-cast joint member;

Fig. 5 is a view similar to Fig. l of a modied joint and wall structurein which the horizontal joints are provided with means for aligning theblocks in a vertical direction;

Fig. 6 is a front elevational view, in partial section, of a part of thewall of Fig. 5;

Fig. 7 is a top plan view of the wall structure, showing a modificationof a vertical joint, by means of which the facing is tied into thebacking wall of brick;

Fig. 8 is a sectional view, taken on the plane of the line 89of Fig. '1,looking in the direction of the arrows, and showing the pre-cast jointmember acting as a tie;

Fig. 9 is a view in perspective of a vertical joint employed in Fig. 8.

Referring to Figs. l to 4, 20 indicates in its entirety a wall structurewhich is made up of glass blocks 2| to 28 and a plurality of pre-castconcrete joint members.

The concrete joint members comprise horizontal joint members 29 andverticaljoint members 30, which are similar in structure, but differentin size. For example, a horizontal joint member is shown in Fig. 4, andit may comprise a pre-cast concrete slab of predetermined thickness,such as one-eighth inch, one-fourth inch, three-eighths inch, one-halfinch, or any desired thickness.

The slab or joint member 29 is -as wide as the depth, front to back, ofthe glass blocks 2l to 28. It is preferably as long as the space takenby the width of two or more glass blocks and the intervening joints.

In the example given, the horizontal joint member 29 is 4long enough tospan two glass blocks and the intermediate joints, but it may -be madelong enough to span any number of joints, or from one to a dozen. Thelimit in length is determined by thickness and strength oi'the slab. Theshorter slabs are preferred on account of ease in handling, packing, andshipping; and if the joints are made llong enough to span two blocks,the horizontal parts of the wall can be effectively tied together bymeans of such joints.

Both of the joint members, horizontal and vertical, are preferablyrectangular in form so that they may b'e fitted together, as shown inFig. 1. The vertical joint members 30 are preferably slightly higherthan the blocks 2| to 28 and as wide as the blocks 2l to 28 are deep.

With regard to the depth of the blocks and the width of the jointmembers, the present pre-cast joint members may be utilized for makingany kind of joints, including flush` joints, raked joints,

suitable reinforcing wire or wire mesh fabric or expanded metal.

The method of laying up a wail of the type shown in Fig. 1 issubstantially as follows: The pre-cast vertical joint members 39 andhorizontal joint members 29 are manufactured in advance at the factoryor suitable plants, and have been set and cured priorto the installationof the wall. They are of the size and characteristics previouslydescribed, and adapted for the particular installation.

'I'he lowermost horizontal joint members 29 are laid upon a flatfoundation wall 35, after first placing upon the wall a thin bed ofmastic 36. This mastic may consist of a Porland cement grout or asuitable thin Portland cement and lime mortar, without sand; or it mayconsist of any initially plastic asphaltic compound which is adapted toprovide a uniform and even bed between the lower plane surface of thehorizontal joint members 29 and the upper plane surface of the concretefoundation 35.

The mortar, grout or mastic fills up the uneven spaces between theserough surfaces, and provides for uniform support of the weight of thesuperstructure.

Where the joint members engage glass blocks, the adhesive asphaltic orpitch composition mastic is used between the glass blocks, and thevertical and horizontal joint members 29 and 30, as at 31, 28.

After the first joint member 29 is laid on the foundation 95, it may becovered 'with a very thin layer of mastic, and the blocks 2li-#28 may belaid in such manner as to break the joints and locate the verticalstruts 30 in between the blocks, with mastic on each side of each joint,and between each part of the block and the joint.

The first course of blocks 25-28 is then covered with the next thinlayer of mastic 39, up to a point which is flush with the upper ends ofthe vertical struts 30, and the next horizontal layer of joint members29 is laid, preferably with the joints of these joint members brokenwith respect protruding joints, -or joints which are later p pointed.

In the embodiment illustrating the invention, the width of the pre-castjoint members locates the outer surface 3| of the joints slightly inward32 of the blocks so that the joint surface 3l :is approximately at theinner termination of the curve 33, which is provided at the corners ofthe blocks. Both of the joint members 29 and 30 are provided withmetallic reinforcing 24, 34', fully embedded in the concrete, and thereinforcing may consist of any not onl to the blocks, but to the coursesof joint members above and below.

It should be noted that the layers of mastic used between the pre-castconcrete joint members andthe glass blocks are so thin that at certainpoints the glass blocks may be n direct contact with the j uint members,and the mastic is used only to provide an even bed and adhesive contactbetween the concrete joints and the glass blocks.

The lowermost horizontal joint members 29 rest on the foundation. Thenext succeeding upper horizontal joint members 29 rest on theintermediate vertical struts 30. The glass blocks rest in therectangular receptacles provided for them between the vertical strutsand the horizontal joint members. J

In effect, each glass block is supported upon a horizontal joint member,which in turn is carried by vertical struts. l

As distinguished from the walls of the prior art, the glass blocks carryno weight except the individual weight of each block. Furthermore, thevertical and horizontal joints are all reinforced with metalreinforcing, and the entire assembly of pre-cast joints fits together insuch manner that an extremely rigid assembly is provided.

The joints between the blocks are perfect in their regularity. depth.and formation. There is no waste of time in waiting for one joint to setbefore laying'another course of blocks. An installation of blocks may bemade in a fraction of the time taken according to the methods of theprior art and with a'minimum waste of material, and a better job isassured.

The strength of the assembly exceeds by far that of any of the glassblock walls of the prior art, and the mastic between the pre-castconcrete joints and the glass blocks permits the expansion andcontraction of the glass blocks without causing destruction of the wall.

The slight amount of contraction and expansion which takes place in eachblock is ,taken up in its own receptacle by the elastic action of themastic compound on all sides of the block.

Referring to Figs. and 6, this is a modification in which the glassblock wall 40 is backed up by a brick wall 4l, and the horizontal jointmembers 42 are preferably provided on the top and bottom with verticallyextending spacing flanges 43 for predetermining the position of thevertical joints.

In this embodiment the vertical anges .43 accurately locate the verticaljoints and serve to maintain the vertical alignment of the struts oneabove the other.

It will be seen that the glass wall may be backed up by a brick Wall andtied to the brick wall according to any of the conventional methods.

Referring to Figs. 7, 8, and 9, this is a modification of the inventionin which the vertical struts 44 are provided with rearwardly extendingtongues 45, having apertures 45A, extending into the joints between thebricks of the backing wall 4|, to tie the facing to the backing wall.

AIn most cases it will be suicient to provide anchor members 'I6 or 'I9at predetermined intervals, or to provide tongues of metal lath 83,which are integrally joined to the metal lath 80 and extend into thejoints of the back wall.

In effect, the structure of Fig. is similar to that of Fig. 5, exceptthe mortar joints are not pre-cast. In every case where my pre-castmortar joints are provided with protruding lugs or ribs at 43v oranchors 45 or extensions 10, 41, or 12, these lugs or extensions, areprovided with reinforcing extensions of the metal lath or otherreinforcing which is employed in the pre-cast joints. Thus there is nodanger of the lugs breaking 01T because they are firmly attached to thebody of the pre-cast joint by reinforcing.

It will thus be observed that I have invented an improved glass wallstructure in which the strength of the completed glass block wall isgreatly increased. The weight ris taken oi the glass blocks and carriedby the concrete struts or joint members, and the joints are uniform inwidth and spaced with a regularity which greatly improves the appearanceof the wall. In the event of the breakage of any glass block, it is onlynecessary to break the block out completely by means of chisels or otherimpact tools, and thereafter a new block may be covered with mastic atits top, bottom, and sides, and slid into the socket, which is vacatedby the broken block. Any excess of mastic may then be removed, andwherever the joint is open, additional mastic applied, so that thereplaced block is made the firm part of the wall.

In the event it is desired to dismantle the wall and preserve the blocksand precast joint slabs intact, it is only necessary to utilize a thinknife blade or a hooked wire, such as an ordinary button-hook, or a wireoi greater length'to dig out the asphaltic or other adhesive compoundbetween the glass blocks and the pre-cast concrete joint members. Oncethis has been done, the blocks may be slid out ol' their sockets; andafter al1 of the blocks, have been removed from the wall, the horizontaland vertical concrete slabs may then be taken apart.

It will also be evident that after one course of glass'blocks has beenremoved, it will be a relatively simple matter to remove the lowersucceeding courses and the concrete joint members. one after another,without necessity for such digging operations. The digging is onlyrequired where all the sides of the block are still confined by mastic.

The present system is not only adaptable to glass blocks. but may beused with ordinary bricks, which may be firmly secured to the pre-castconcrete joints by means of grout used as mortar, instead 0f the masticwhich is employed with glass blocks.

While I have illustrated a preferred embodiment of my invention, manymodifications may be made without departing from the spirit of theinvention, and I do not wish to be limited to the precise details ofconstruction set forth, but desire to avail myself of all changes withinthe scope of the appended claims. i

Having thus described my invention, what I claim as new and desire tosecure by Letters Patent of the United States, is:

1. In a, wall structure, the combination of a rigid supporting frameworkcomprising a plurality of horizontally extending pre-cast concrete slabmembers adapted to serve as horizontal joints, and a plurality ofvertically extending precast concrete slab members adapted to serve asvertical joints, said slab members having their largest surface areassubstantially plane, and said horizontal slab members being spaced fromeach other by a distance slightly greater than the vertical depth ofbuilding blocks to be used in said structure, and said vertical slabsbeing spaced from each other by a distance slightly greater than thehorizontal width of the build ing blocks to be used in said structure,said structure being built up alternately of horizontal slab members,and a series of vertical slab members supporting succeeding horizontalslab members and forming box-like recesses of a size adapted to slidablyreceive building blocks `of vitreous material or the like, whereby thebuilding blocks do not support any load other than each block supportingits own weight, and the load of the upper courses is carried by thehorizontally extending slab members and the vertically extending slabmembers, the latter serving as struts, a plurality of building blocks insaid recesses, and a sticky adhesive compound adapted to adhere to thebuilding blocks and to the concrete slab members, lling the spacebetween the sides of each building block and the adjacent walls of theslab members, whereby the structure is made watertight and each block iscaused to adhere to the walls of its recess in the framework, saidhorizontal slab members being formed with vertically extending portionsof substantially the same width as the vertically extending slab membersand adapted to support the vertically extending slab members and todetermine their location.

2. In a Wall structure, the combination of a rigid supporting frameworkcomprising a plurality of horizontally extending pre-cast concrete slabmembers adapted to serve as horizontal joints, and a plurality o!vertically extending precast concrete slab members adapted to serve asvertical joints, said slab members having their largest surface areassubstantially piane, and said horizontal slab members being spaced fromeach other by a distance slightly greater than the vertical depth ofbuilding blocks to be used in said structure, and said vertical slabsbeing spaced from each other by a distance slightly greater than thehorizontal width of the building blocks to be used in said structure,said structure being built up alternately of horizontal slab members,and a series of vertical slab members supporting succeeding horizontalslab members and forming,

box-like recesses of a size adapted to slidably receive building blocksof vitreous material or the like, whereby the building blocks do notsupport any load other than each block supporting its own weight, andthe load of the upper courses is carried by the horizontally extendingslab members and the vertically extending slab members, the latterserving as struts, the horizontal slab members in each course comprisinga plurality of sections of a length sufficient to span more than oneblock, and the ends of the sections forming abutting joints betweenhorizontal slab members, intermediate between the side walls of thebuilding blocks, and vertically extending portions located above andbelow said horizontal slab members and forming shoulders between whichthe building blocks must be located to predetermine the alignment of thejoints in the wall.

3. In a wall structure for vitreous blocks, the combination of asupporting wall member of bricks or the like, said bricks being arrangedin regular courses and having their joints arranged to coincide withcertain of the joints of a front wall structure, said front wallstructure comprising a plurality oi vitreous building blocks, and aplurality of horizontal and vertical joint members of reinforcedconcrete, said horizontal joint members comprising slabs of concrete ofa thickness substantially equal to the thickness of the joint desiredand of a width corresponding substantially to the depth of the vitreousbuilding blocks, each of said horizontal joint members extending betweena plurality of blocks, and the joints between said horizontal jointmembers being intermediate the vitreous blocks, said horizontal jointmembers also having upwardly extending and downwardly extending jointshoulders located between the vitreous blocks and adapted to engage thevertical joint members comprising concrete slabs of substantiallyrectangular shape adapted to rest upon the upwardly extending -portionsof said horizontal joint members and to engage the downwardly extendingportions of the horizontal joint members of the next upper course, thusforming a plurality of recesses of a cross section adapted to t saidvitreous building blocks with a clearance, and an initially plasticmastic compound engaging the walls of said recesses, and providing a bedfor the vitreous building blocks against the concrete joint members andiilling in said clearance, said mastic compound also serving tostrengthen the assembly and to hold the complete structure of buildingblocks and joint members in predetermined shape, whereby the blocks areall supported upon the framework of the joint members without bearingany other weight than their own weight and any block may be replaced byremoving the mastic surrounding it. 4. In a wall structure for vitreousblocks, the combination of a supporting wall member of bricks or thelike, said bricks being arranged in regular courses and having theirjoints arranged to coincide with certain of the joints of a front wallstructure, said front wall structure comprising a plurality of vitreousbuilding blocks, and a plurality of horizontal and vertical jointmembers of reinforced concrete, said horizontal joint members comprisingslabs of concrete of a thickness substantially equal to the thickness ofthe joint desired and of a width corresponding substantially to thedepth of the vitreous building blocks, each of said horizontal jointmembers extending between a plurality of blocks, and the joints betweensaid horizontal joint members being intermediate the vitreous blocks,said horizontal joint members also having upwardly extending anddownwardly extending joint shoulders located between the vitreous blocksand adapted to engage the vertical joint members comprising concreteslabs of substantially rectangular shape adapted to rest upon theupwardly extending portions of said horizontal joint members and toengage the downwardly extending portions of the horizontal jointmember.r of the next upper course, thus forming a plurality of recessesof a cross section adapted to fit said vitreous building blocks with aclearance, and an initially plastic mastic compound engaging the wallsoi said recesses, and providing a bed for the vitreous building blocksagainst the concrete joint members and iilling in said clearance, saidmastic compound also serving to strengthen the assembly and to hold thecomplete structure of building blocks and joint members in predeterminedshape, whereby the blocks are all supported upon the framework of thejoint members without bearing any other weight than their own weight andany block may be replaced by removing the mastic surrounding it, certainof said strut members having rearwardly extending extensions anchored insaid first-mentioned supporting wall whereby the forward wall structureis carried and supported by the rear wall structure.

RUDOLPH KALKUSCH.

